Carrier or felting needle



Aug. 3, 1943. I c. J. KOPRIVA ET AL 2,326,038

CARRIER OR FELTING NEEDLE Filed March 4, 1940 F g.8. F3 5. F g. 4.

2 i Z/ Z/ Z/ Z9 F25 E 210. Ii Elli. 75 zz q 4 1; 25 L 5 J K E T" E u 1 I l g 23 y Z3 Z5 BPgNA ATE Z4 Z4 14 W l h 6 ATTORNEY Patented Aug. 3, 1943 Charles J. Kopriva, Bloomfield, and Percival '1.

Gates, Montclair, N. J., assignors to Drycor' Felt Company, Belleville, N. J., acorporation of New Jersey Application March 4, 194% Serial No. 322,156

6 Claims.

The present invention relates to an improved carrier or felting needle, particularly of the type adapted to be used in a machine for carrying or impregnating fleece or other fibrous material'into a base structure, either inthe form of woven fabric or of other suitable form.

Previously known needles for this purpose usually consist of a cylindrical wire formedat its fleece carrying end into triangular cross-section, the edges of this triangular portion being provided with a series of barbs, usually formed by swedging the metal. This particular type of needle has several objections, for example, the 'tri-. angular cross-section is such thatin entering the rectangular interstices of the woven base fabric, one or more of the barbed edges will contact the strands of the base fabric between the crossing points or knuckles causing the fibrous strands to become loosened, picked, out or otherwise damaged tending to weaken the base structure. Also the swedging ofthe barbs for carrying the fleece causes the'metal to project slightly with respect to the vertical edges of the needle, thus increasing the danger of cutting into the strands of the cloth and preventing the smooth, easy insertion and withdrawal of the needle.

The triangular cross-section needle having only three edges, limits the number of barbs and consequently the amount of ifieece carried with each stroke. Attempts have been'ma'de heretofore to increase the number of effective barbs upon a felting needle by twisting the wire into spiral form, so that the edges containing the barbs are spirally arranged. In this case however, the barbs are in such position with relation to the square interstices of the cloth that they cut across the strands between'the corners to an even greater extent than isthe case with the t'ri angular cross-section straight-edged needles.

It is an object of the present inventionto provide a carrier or felting needle which is ofsirng ple and rugged construction, and which will so cooperate with thebase cloth of the fabric that in entering the interstices the portions of the strands between the corners will be effectually protected against engagement by the; barb. To

angularly bent end of the needle; which secures 7 it in the carrier head, that the, sides of the square cross-section will be parallel to; the fabric warp and fill strands. Thus in entering the interstices the vertical edges of the needle containing the barbs will be disposed in the corners of the interstices'and the strands ofthe warp and fill will therefore be effectually protected against damage from being nicked or plucked. by the barbs,

It is further proposed inone embodiment of the invention to provide the needle with bulged or rounded sides so that in entering the interstices the opening will be spread at its four sides, the intermediate portions of the strands being thus supported upon the peaks of the bulges'and providing free spaces at the corners for the effectual unrestricted insertion and withdrawal of the barbed edges-carrying the-fleece fibres.

It is further proposed to provide 'a needle having a tapered entering or pilot point to facilitate engagement with the interstices; and to form an entry for the bcdyof the needle, the square body thereupon completing the form before the entryof the fibre catching notches or barbs. 'It is also proposed, as one embodiment of the invention, to provide the notched or barbed portion of the needle in the form of a tapered shaft which will gradually enter and spread the interstices, and will also have the effect of carrying a greater amount of fleece, the fleece building up rapidly in quantity as the thickness or vertical ofiset of the needle 'increases. This tapered form of needle also insures the efieotual. removal of the increased amount of fleece during the withdrawal of the needle because of the increased tension of thea barb formation produced by an acute angle slot having its downwardly directed upper cornerso rounded that there will be no chance of it catching on or cutting into the-fabric, and

having its upwardly directed lower corner so curved into the edge'that the fleece will slip smoothly out of the notch during withdrawal of the needle.

. It is further proposed to provide a needle having an increased number; of barbs, and also to arrange the barbs'in staggered relation so that at no one point will theyv be opposite each other, and therefore the increase in the number of barbs will not impair the strength of the needle.

With the above other objects in View, embodiments of the invention are shown in the accompanying; drawing, and these embodiments will be hereinafter more fully described with ref erence thereto, and the invention will be finally pointed out in the claims.

In the drawing:

l. is a vertical sectional view of an exemplary form of needle bar provided with two rows j of needles, according to the invention.

Fig. 2 is a side elevationof a needle according to the invention, and having a tapered fleece carrying end portion.

Fig. 3 is a front elevation thereof.

Fig. 4 is a front elevation of a modified form of needle in which the fleece carrying portion has straight parallel sides.

5 is an enlarged fragmentary detail view of the fleece carrying end portion of the type of needle, shown in Figs. 2 and 3, and turned to a position 90 removed from the side and front elevations shown in Figs. 2 and 3. r

Fig. 6 is a sectional view along the line S6 of Fig. 5.

7 is a sectional plan View showing the woven strands of a piece of base fabric surrounding a mesh opening thereof, and which is engaged by the pilot or entering point portion of the needle.

Fig. 8 is a similar view showing the needle fully engaged and the strands moved thereb into spread relation. I

Fig. 9 is a side elevation of the lower end portion of a modified form of tapered side needle, and in which the side surfaces are flat, as distinguished from the bulged or rounded surfaces of the embodiment shown in Figs. 2 and 3.

' Fig. 10 is a sectional view, along the line lili ll of Fig. 9.

Fig. 11 is a side elevation of 'another modified form of needle having straight parallel sides. and in which the side surfaces are flat, as distinguished from the bulged or rounded surfaces of the embodiment shown in Fig. 4.

Fig. 12 is a sectional view, along the line l2i2 of Fig. 11. r

Similar reference characters indicate correspending parts throughout the several figures of the drawing.

Referringparticularly to Fig. l, the needles, according to the invention, are adapted to be mounted in a suitable carrier head of a needling machine, such head, as shown in the exemplary illustration, consisting of an elongated horizontal needle bar iii supported upon vertical rods H, and provided with a downwardly depending web I 2, at each side of which there is secured a needle carrying strip 53 augularly recessed, as at M, to receive the an ularly bent upper ends of the needles, hereinafter more fully referred to, the upper ends of the needles being vertically supported in spaced parallel relation by a grooved or serrated needle carrying plate !5, which has the needles disposed in the grooves or serrations thereof, and which is fitted into the recess I l and retained therein by means of screws l6 carried in the side plate 5? of the needle bar. --In 7 operation the needle bar has simultaneous vertical reciprocatory and horizontal to and fro movement, so that the needles rnovein an oval path, the woven base fabric is to which'the bat of fleece I9 is to be needled being moved by the machine in synchronism with the horizontal movement of the needle bar, so that as the base cloth is fed forwardly in the machine the needles move with it. A machine of this general type is disclosed in the patent to Patrick H. Walsh, No. 1,620,307, dated March 8, .LQZT.

, The needle according to the invention, and as disclosed particularly in Figs. 2 and 3, is formed of substantially square cross-section wire having the side surfaces slightly bulged or rounded as shown clearly in Fig. 6, the needle consisting of an upper shaft portion 26 provided at its upper end with a right angularly bent securing end 2i, and having a fleece carrying lower end portion 22 g which is slightly tapered downwardly, the lower end terminating in a point or pilot portion 23 which is of square cross-section, but which may if desired, be rounded, and which dwells into a rounded or dulled point 24. The end 2! is bent across a flat surface of the wire so that when mounted in the needle bar the needle will be so disposed that its substantially rectangular crosssection will be parallel to and fit the rectangular mesh. openings of the base fabric A. series of fleece carryin notches 25 is formed in each of the four edges of the portion 22, these beingpreferably formed by removing the metal from the needle, as distin uished from previous 'methods where the notch has been formed by swedging. A suitable method is to produce the notches by saw-cuts, each notch being cut at an acute upwardly and inwardly inclined angle. The downwardly directed point of the upper face of the notch, which forms a fleece picking-up barb is dulled. or rounded, as at 26, so that in entering the base fabric there will be no sharp or projecting point which will catch into the fibres of the warp and fill strands of the fabric. The corner between the lower face of the notch and the vertical edge of the needle is convexly rounded, as at 2;, so that during withdrawal of the needle the fleece will be effectually removed without catching into the notch. The notches are so staggered spirally that they are substantially evenly spaced and do not come opposite each other, and therefore the needle is of substantially uniform strength along itsportion 22.

The width of the notches is substantially less than the diameter of the threads or strands of the base fabric so that there is no possibility of the notches catching thereon. While the notches are shown as having substantially parallel upper and lower facesitwill be understood that they may if desired diverge inwardly.

In the modification shown in Fig. 4 the fleece carrying portion 22 of the needle has straight parallel sides. as distinguished from the tapered sides of the needle shown in Figs. 2 and 3. In practice the tapered needle will be employed for use with heavy material and to carry an increased amount of fleece into the fabric. It will be understood that as the needle moves vertical- 1y downwardly through the fleece the tapering arrangement of the sides with the notches outwardly offset toward the top will cause an increased amount of the fleece to build up and be caught by the notches. The straight or parallel sided needle, as shown in Fig. 4, will preferably be used for lighter duty.

In Figs; '7 and 8 there is illustrated the cooperative engagement of the bulging sided needle, of either of the types shown in Figs. 2 and 3, or Fig. 4. .As shown in Fig. 7 the pilot point 23 is first loosely engaged in the mesh opening and causes the needle to be positively guided therein accepts and thereupon tor-ms the entry for the body of the needle, the bulging sides of which complete the form before entry of the barbs or'notches; As the thickness of the needle increases its sides wedgingly engage the sides of the mesh opening and the bulged surfaces of the needle cause the mesh opening to spread slightly, as shown in Fig. 8. *In spreading the intermediate points of the strands between the corners of the mesh opening engage upon the peaks of the bulging sides of the needle, the curvature of which is such that at the corners there will be produced clearance spaces, as indicated at 28, so that the barbed or notched edges of the needle which carry the fleece hooked therein will not snag or catch upon the strands but will move freely into the mesh opening. In the case of a mesh opening which is not spread by the bulged sides of. the needle the free spaces at the corners will be slightly larger. withdrawal of the needle the tension produced in the strands through the slight spreading action will insure completefremoval of the fleece and retention thereof in the mesh opening.

In the case of the tapered needle the spreading will increase proportionately as the needle moves into the fabric, and as a consequence there will be a relatively greater spreading and increased tension produced in the strands, which will insure removal of theincreased amount of fleece carried by the tapered needle. The tapered needle also facilitates withdrawal of the needle, this being particularly important in the case of working with coarse, tough base material.

In Figs. 9 and 10 I have'illustrated a modified form of the invention in which the tapered fleece carrying portion 22 of the needle has flat sides, as distinguished from the bulged or rounded sides of the embodiment illustrated in Figs. 2 and 3.

In Figs. 11 and 12 I have illustrated a further modification in which the straight parallel sided fleece carrying portion 22 of the needle is provided with flat sides, as distinguished from the bulged or rounded sides of the embodiment illustrated in Fig. 4.

After formation of the needle, that is shaping and slott ng, it is surface hardened, so as to increase its smoothness and resistance to wear.

The needle of the invention has been referred to as a carrier needle because this is an important use to which it is put in the manufacture of felt and padding material in which wool fleece, or the like, is needled into a woven base fabric. The needle may however be used-for the facing or impregnating of other types of cloths and other base materials, and is not limited to use with fleece, but may be employed for the needling of any other material to which it may be adapted. With reference to the base materials it is pointed out that instead of woven fabric the base may be of other form. For instance it may be a substance having a grained texture, in which case the needles may be so disposed that their flat sides will be aligned with the grain.

While we have illustrated the bent end type of mounting head 2!, it will be understood that other types of heads may be employed for the purpose of locating the needle in the carrier head in a predetermined aligned position with respect to the weave or grain of the base material.

We have illustrated and described a preferred and satisfactory embodiment of the invention, but it will be obvious that changes may be made therein, within the spirit and scope thereof, as defined in the appended claims.

Upon

Having thus described the invention, what we claim and desire to secure by Letters Patent is:

'1. As a new article of manufacture, a felting needle having a body of substantially uniform cross section provided with downwardly and outwardly inclined slots each having a lower wall, an upper wall of considerable length substantially parallel to said lower wall and a top wall in a plane connecting said upper and lower walls; said slotsbeing open at their lower ends and providing downwardly directed spurs on said body.

2. As a new article of manufacture, a felting needle having a body of substantially uniform cross-section provided with downwardly and outwardly inclined slots each having a lower wall, an upper wall of considerable length substantially parallel to said lower wall and a top wall conmeeting said upper and lower walls and of a width substantially corresponding to the spacing of the top ends of said upper and lower walls, said slots being open at their lower ends providing downwardly directed spurs on said body.

3. As a new article of manufacture, a felting needle having a body of substantially uniform cross-section provided with downwardly and outwardly inclined slots each having a lower wall, an upper wall of considerable length substantially parallel to said lower wall and end wall means connecting said upper and lower walls at their spaced top ends, said slots being open at their lower ends providing downwardly directed spurs on said body.

4. A carrier or felting needle for carrying fibrous material into woven base cloth wherein warp and weft strands are disposed at right angles to each other and are coarsely woven to produce substantially Square mesh openings, comprising a body having four longitudinal side walls of equal width and connected at corners each disposed in a longitudinal line coincident with a plane of the central longitudinal axis of the body, the width of said side walls being such that said body is adapted to be engaged through a mesh opening of'said base cloth with the diagonals extending between opposed corners of said body being also extended between the opposed corners of the mesh opening, each of said corners having fibrous material catching upwardly and inwardly inclined notches therein adapted to carry fibrous material into the mesh opening without contact of said notched edges with the portions of the warp and weft strands of the cloth extending between the corners of the mesh opening, th side walls of said body being convexly curved transversely between said corners and adapted to spread the opposed parallel strands of the cloth between the corners of the mesh opening to space the corners of the body from the corners of the mesh openings.

5. A carrier or felting needle comprising a body having a point end and four longitudinal side walls extending upwardly from said point end and connected at corners each disposed in a longitudinal line coincident with a plane of the central longitudinal axis of the body. each of said corners having fibrous material catching notches therein inclined; upwardly and inwardly and disposed entirelyinwardly of the surfaces of said side walls and the longitudinal lines of said corners.

6. The method of producing ncedled fabric which comprises feeding longitudinally a length of woven base cloth wherein coarsely woven warp and weft strands are disposed at right angles to each other to produce substantially rectangular mesh openings, needling fibrous material into said base-cloth by reciprocating needles wherein the body of each such needle is provided'with a point end and four longitudinal side Walls extending upwardly from said point end and connected at corners each disposed in a longitudinal line coincident with a plane of the central longitudinal axis of the body,.and wherein said corners are provided with fibrous material catching notches inclined upwardly and inwardly and disposed entirely inwardly of the surfaces of said side walls and the longitudinal lines of said corners, arranging said needles with their side Walls in line with the Warp and Weft strands, and engaging said needles during reciprocation with the mesh openings of said base cloth to carry the fibrous material into the mesh openings without contact of said notches with the portions of the warp and weft strands extending between the corners of the mesh openings.

. CHARLES J. KOPRIVA.

PERCIVAL T. GATES. 

